The Impact of Lower Quality Process Materials on Manufacturing Equipment Downtime

IDCON INC, Reliability and Maintenance Consulting and Training

Posted 1/16/2024

What is the impact of lower quality process materials on manufacturing equipment downtime? Low-quality process materials can significantly impact manufacturers by causing production delays, increased defects, higher maintenance costs, and a decrease in the overall quality of the final products. It can lead to waste, higher rejection rates, and damage to machinery, affecting both the efficiency and reputation of the manufacturing process.

Manufacturing industries rely heavily on the quality of their materials to ensure a smooth production process. When lower quality materials are introduced, it can have significant repercussions, particularly on manufacturing equipment downtime. The repercussions of using subpar materials can result in increased equipment downtime, affecting the efficiency and productivity of the entire manufacturing operation.

Effects on Manufacturing Equipment Downtime

Increased Wear and Tear

Low-quality materials often lack the necessary durability and resilience required for the machinery. This leads to increased wear and tear on equipment, causing frequent breakdowns and necessitating more frequent maintenance.

Malfunction and Breakdowns

Subpar materials can result in the malfunctioning of machinery or even sudden breakdowns. This not only halts the production process but also demands immediate attention and repair, contributing to prolonged equipment downtime.

Inefficient Performance

Manufacturing equipment functions optimally when supported by high-quality materials. The use of lower quality materials can lead to inefficiencies, decreasing the overall productivity and throughput of the manufacturing process.

Determining if Low-Quality Materials are the Problem

Identifying the root cause of increased equipment downtime due to low-quality materials requires a comprehensive approach. Here are some methods to determine if the materials used are causing issues:

Performance Monitoring

Regular monitoring of equipment performance against the specified benchmarks can highlight deviations caused by material quality issues. Any discrepancies can be further investigated to ascertain if materials are the cause.

Quality Testing

Implementing stringent quality control measures such as material testing and analysis can reveal discrepancies in the expected and actual material properties. Testing for durability, strength, and composition can uncover if the materials are below standard.

Comparative Analysis

Comparing the performance and longevity of equipment when using different grades or sources of materials can pinpoint any discrepancies arising from the quality of the materials.

Supplier Evaluation

Assessing the consistency and reliability of materials obtained from different suppliers can help identify if a particular source or grade of materials is causing issues.

Historical Data Analysis

Reviewing historical records of equipment performance and downtime can indicate correlations between material changes and increased downtime.


The impact of lower quality process materials on manufacturing equipment downtime is substantial. To mitigate these challenges, it is crucial to implement stringent quality control measures, regular testing, and thorough supplier evaluations to ensure that only high-quality materials are utilized in the manufacturing process. By addressing the root cause of equipment downtime related to material quality, manufacturers can enhance efficiency, reduce costs, and maintain a high standard of production.



IDCON INC provides side-by-side reliability and maintenance consulting and training designed to keep your equipment running. For over 45 years, they have partnered with hundreds of manufacturing plants around the world to eliminate the costs and the pressure caused by unreliable equipment.

They offer in person and online reliability and maintenance, spare parts management, planning and scheduling, shutdown/turnaround optimization, preventive maintenance and root cause problem elimination training; strategic consulting and coaching; and provide a number of free online resources. Run your plant, don't let it run you.

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